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BIFFI ITALIA ELGA – Scotch Yoke Reducer Instruction and operating manual

A© Copyright by BIFFI Italia. All right reserved MAN 687/Rev.1 Page i

MAN 687

ELGA – Scotch Yoke Reducer

Instruction and Operating Manual

1 20/Oct/2011 General Revision G. Inzani A.Ghiadoni L. Vigliano

0 12/Dec/2008 Issue S. Orefici A.Ghiadoni L.Vigliano

Rev. Date Description Prepared Checked Approved


A© Copyright by BIFFI Italia. All right reserved MAN 687/Rev.1 Page i Page i

INDEX

1 GENERAL SAFETY INSTRUCTIONS ........................................................................ 4

1.1 Manufacturer 4 1.2 Machine Intended Use 4 1.3 Terms and conditions 5 1.4 Manufacturer’s Liability 5 1.5 Applicable Standards and Regulations 5 1.6 Installation in hazardous area 5 1.7 Marking for application in hazardous area 6

1.7.1 Label for ICON2000/ICON2000EC ...............................................................................................................6

1.7.2 Extract from the Standard ............................................................................................................................6

2 MACHINE DESCRIPTION ........................................................................................ 7

2.1 General 7 2.2 Main Parts Description 8

3 TECHNICAL DATA..................................................................................................... 9

3.1 Application range 10

4 TRANSPORT AND STORAGE ................................................................................. 10

4.1 Transport 11 4.2 Checks to be carried out on receipt of the ELGA reduction unit 11 4.3 Storage Procedure 11

5 INSTALLATION ....................................................................................................... 12

5.1 Working condition 12 5.2 Safety Instructions for installation in Hazardous Area 12

5.2.1 Instructions for the explosion-proof enclosures ................................................................................... 12

5.2.2 Installation in ambient with explosive dusts ......................................................................................... 12

5.3 ASSEMBLING the ELGA unit onto the VALVE 12

6 MAINTENANCE ....................................................................................................... 14

6.1 Standard Maintenance 14 6.2 Special Maintenance 14

7 LUBRICATION ........................................................................................................ 16

8 ADJUSTING THE MECHANICAL STOPPERS ........................................................ 17

9 DISMANTLING AND DEMOLITION ...................................................................... 18


A© Copyright by BIFFI Italia. All right reserved MAN 687/Rev.1 Page ii Page ii

10 PARTS LIST ......................................................................................................... 19

10.1 How to Order Parts List 19

BIFFI ITALIA has taken every care in collecting and verifying the documentation contained in this Instruction

and Operating Manual.

The informations herein contained are reserved property of BIFFI ITALIA.

Contents may change without notice.


A© Copyright by BIFFI Italia. All right reserved MAN 687/Rev.1 Page 4

1 GENERAL SAFETY INSTRUCTIONS

1.1 Manufacturer

Manufacturer with respect to the Machinery Directive 2006/42/EC is BIFFI ITALIA, as specified on the

machinery label.

1.2 Machine Intended Use

The machines to whose this Instruction and Operating Manual applies are the ELGA series (ON-OFF

Type), which are designed to operate industrial valves with a 90° rotary stem (such as ball, butterfly, plug

valves and others) for use in applications in heavy industrial, chemical, petrochemical, food, water and

power generating plants. They are designed for motor operation in conjunction with ICON 2000 electric

actuators.

BIFFI ITALIA will not be liable for any possible damage or physical injury resulting from use in other than the

designated application or by lack of care during installation, operation, adjustment and maintenance of the

machinery. Such risks lie entirely with the User.

Depending on the specific working conditions, additional precautions may be required.

The ELGA are produced by BIFFI ITALIA and identified on the proper label by the product designation:

ELGA-XXKR.

Important

This Manual gives basic information for ELGA series setting; more detailed

information for setting and control of the Electric Actuator ICON2000 are

included on the MAN 618 which form part of the mandatory instructions

documentation.

Warning

It is assumed that the installation, the setting, the commissioning and the

maintenance and repair works are carried out by qualified personnel and

checked by responsible Specialists.

Warning

Read this installation and maintenance manual carefully and completely

before attempting to store or install the operator. If an electric operator is

attached to the ELGA operator, be aware of the electrical hazards and consult

the relevant electric actuator installation and maintenance manual for

guidance.

The ELGA series are designed in accordance with the applicable International Rules and Specifications but

in any case the following Regulation must be observed:

the general installation and safety regulations

the plant specific regulations and requirements

the proper use of personal protective devices (glasses, clothing, gloves)

the proper use of tools, lifting and transport equipment.



1.3 Terms and conditions

BIFFI ITALIA guarantees each single product to be free from defects and to conform with current goods

specifications and regulations as applicable. The warranty period is 12 months from the date of installation

by the first User or 18 months from the date of shipment to the first User, whichever occurs first. No

warranty is given for products, which have been subject to damages or corrosion due to the improper

storage, improper installation, misuse, or which have been modified or repaired by unauthorised personnel.

Repair work due to improper use will be charged at standard rates.

1.4 Manufacturer’s Liability

Biffi Italia declines all liability in the event of:

use of the machinery in contravention of local safety at work legislation.

incorrect installation, disregard or incorrect application of the instructions provided on the product

nameplate and in this Instruction and Operating Manual.

modification of the product without Biffi’s authorisation.

work done on the product by unqualified or unsuitable personnel.

1.5 Applicable Standards and Regulations

EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design.

Part 1-Basic terminology, methodology.

EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design.

Part 2-Technical principles and specification.

2006/42/EC Machinery Directive.

ATEX 94/9 ATEX Directive

1.6 Installation in hazardous area

Warning

In case the ELGA are to be installed in HAZARDOUS AREA, as defined by the

applicable Rules, it is mandatory to check if the nameplates of the

associated ICON2000/ICON2000EC specify that the assembly is suitable to

be installed in HAZARDOUS AREA with the indication of appropriate degree

of protection.

Maintenance and repair works must carry out by qualified personnel and

checked by responsible Specialists.



1.7 Marking for application in hazardous area

1.7.1 Label for ICON2000/ICON2000EC

The ICON 2000/ICON 2000 EC associated to the ELGA, for the application in hazardous areas, has to present

a label with the following marking description:

0080 = Notified Body for ATEX

II = Group II (Surface)

2 = Category 2 apparatus

G = explosive atmosphere by gas

D = explosive atmosphere by dust

IP 66/68= degree of protection

1.7.2 Extract from the Standard

Type of Hazard Classification of Zones Categories acc. to 94/9/EC Directive

Gas, mists or vapours Zone 0 1G



Dust Zone 20 1D

Dust Zone 21 2D

Dust Zone 22 3D



2 MACHINE DESCRIPTION

2.1 General

The ELGA is a slotted link mechanism which transforms the motion impressed by the ICON 2000 electric

actuator into a rotating motion, in order to operate industrial valves with a 90° rotary stem (such as ball,

butterfly, plug valves and others). The mechanical stoppers allow angular stroke adjustment within 5°.

A spur gear reduction unit is placed between scotch yoke mechanism and electric actuator in order to

increase input torque.

Particular feature of the ELGA unit is the remarkable high reliability obtained, and this thanks to the adoption

of a particularly simple, rugged and very rigid construction. With constant input torque, the scotch yoke

mechanism determines a parabolic curve of the output torque in function of the angular stroke with

maximum values at 0° and 90° almost 1.70 times larger than minimum value at 45°.

The particular care undertaken to minimize sliding and rolling friction has allowed the manufacture of a

highly efficient gear, making easier the operation of valves requiring high torque values.

The ELGA scotch yoke mechanism has a special grease lubrication of its mechanical parts, enough for the

entire life of the unit.

TORQUE DIAGRAM

The ELGA series gives an output torque with symmetric parabolic rent.

It is very important for a correct choice of the operator to know the valve torque values along the valve

stroke.

NOTES:

1) The above diagram is only qualitative and indicate the relation between the torque values in the

most important points of the angular stroke.

2) The diagram is intended considering a constant input torque, all along the stroke.



2.2 Main Parts Description

Picture 1

ICON Electric Actuator

Reduction Unit

Scotch yoke Mechanism

Mechanical Local Position Indicator

Mechanical Stopper



3 TECHNICAL DATA



3.1 Application range

ELGA reduction units are suitable to be motorized for applications in standard temperature range from –30°C

to +85°C.

The ELGA reduction units have protection degree IP67 accordingly to EN 60529.

4 TRANSPORT and STORAGE

Important

Not performing the following procedures will invalidate the product

guarantee.

Important

ELGA reduction unit (and actuator) lifting and transportation has to be done

by qualified personnel only and in accordance to the local regulation and

area classification.

Warning

The actuator and ELGA reduction unit weight are reported on the

transportation documents.



4.1 Transport

Transport the ELGA reduction unit to place of installation in strong packing.

If the ELGA reduction unit is mounted together with the electric actuator, lift it by hoist with ropes or

hooks attached only to the reduction unit and not to the actuator ( see picture )

4.2 Checks to be carried out on receipt of the ELGA reduction unit

Carefully remove the ELGA reduction unit from shipping carton or skid. Check that it has not been

damaged during transportation. If damaged, immediately report the damage to the transport company.

Check first of all if the information written on the nameplate (Model, Nominal torque, Degree of

protection,…) correspond with the data of the product which is expected.

Check that the model, the serial number of the ELGA reduction unit and the performance data written on

the data-plate are in accordance with those described on the order acknowledgement, test certificate

and delivery note.

Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery

note.

4.3 Storage Procedure

Important

The following is the requested storage procedure to maintain maximum ELGA

integrity during storage; failure to comply with recommended procedure will

invalidate the warranty.

The ELGA reduction units leave the factory in excellent working conditions and with an excellent finish (these

conditions are guaranteed by an individual inspection); in order to maintain these characteristics until it is

installed on the plant, it is necessary to observe a few rules and take appropriate measures during the

storage period.

Store in well-ventilated, protected, dry room.

Store the ELGA reduction units on wooden skids or on shelf to protect the machined mounting flange.

If the ELGA are supplied separately from the valves, they must be placed onto a wooden pallet. In case

of long-term storage (over six months), the ELGA reduction unit must be covered to protect it against

dust and dirt, and it is necessary to apply suitable corrosion protection agent to bare surfaces, and in

particular to the output drive parts and mounting surfaces.

In case of long-term storage, it is advisable to keep the ELGA reduction units in a clean, dry place in

order to provide at least some means of weather protection.

If the ELGA reduction units have to be stored outside, they must be protected adequately (for example

covered in polyethylene protection with silica gel crystals to absorb moisture).

For the storage of the Electric Actuator supplied together with the ELGA reduction unit, please refer to the

storage instructions included in the actuator’s IOM (MAN 618).



5 INSTALLATION

5.1 Working condition

The standard ELGA reduction units are suitable for the following ambient temperatures:

from -30°C to +85°C (from -22°F to +185°F)

The low temperature version is suitable for temperature ranges from -60°C to +65°C

Important

Check the "temperature ambient range" embossed on the nameplate, for the

correct utilisation with respect to the ambient temperature.

Installation in ambient with temperature range outside the specified values

will invalidate the warranty.

5.2 Safety Instructions for installation in Hazardous Area

5.2.1 Instructions for the explosion-proof enclosures

Important

For the installation of the assembly ELGA - Electric Actuator in hazardous

areas, please refer to the instructions included in the Electric Actuator IOM

(MAN 618).

5.2.2 Installation in ambient with explosive dusts

Important

For the installation of the assembly ELGA - Electric Actuator in ambient with

explosive dusts, please refer to the instructions included in the Electric

Actuator IOM (MAN 618).

5.3 ASSEMBLING the ELGA unit onto the VALVE

The ELGA unit is provided with an output flange and an insert (machined or not machined, based on Customer

requirements) for the coupling to the valve. The assembly position (orientation) of the valve/actuator (gearbox)

package must comply with the plant requirements.

To assemble the actuator onto the valve proceed as follows:

Check that the valve coupling dimensions of the flange and stem, or of the relevant extension, meet the ELGA

coupling dimensions.

Arrange the valve in the position related to the ELGA operation (for both butterfly valves and ball valves the

recommended position is OPEN).



Lubricate the valve stem with oil or grease in order to make the assembly easier: be careful not to contaminate

with lubricant the flange surfaces which have to be connected to transmit the actuator torque.

Clean the valve flange and remove anything that might prevent a perfect adherence to the ELGA flange and

especially all traces of grease.

If the insert supplied is not machined, remove it from the ELGA output drive, machine it and reassemble it in

the ELGA output drive.

Bring the ELGA to the recommended position (for both butterfly valves and ball valves the recommended

position is OPEN).

Clean the ELGA flange and remove anything that might prevent a perfect adherence to the valve flange and

especially all traces of grease.

Lower the actuator/ELGA package onto the valve so that the ELGA output drive couples with the valve stem

(for example, if the connection is made by key, the valve stem key groove must match with the ELGA output

drive key groove). This coupling must take place without forcing and only with the weight of the actuator and

ELGA. When the ELGA output drive and the valve stem are connected, check the holes of the valve flange.

Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in the table. If no different

materials are specified, the stud bolts must be made of ASTM A 320 Grade L 7 steel, the nuts must be made

of ASTM A 194 Grade 2 or better.

Thread size Recommended tightening

torque (Nm)

M16 160

M20 320

M22 420

M24 550

M27 800

M30 1100

M36 1700

If possible, operate the actuator to check that it moves the valve smoothly.



6 MAINTENANCE

Warning

All installation, start-up, maintenance and repair works must be made by

specialised personnel.

6.1 Standard Maintenance

BIFFI ELGA reduction units require no special maintenance.

After commissioning and once per year, check all the paint-coat of the ELGA. If some areas

are damaged, repair the paint-coat according to the applicable specification.

In chemically aggressive or saline environments, remove rust from surfaces and protect

with a rust preventative.

Approx. six months after commissioning and once per year, check that the nuts and bolts

securing the ELGA to the electric actuator and to the valve are tight, and, if necessary, re-

tighten.

Approx. every 2 years perform a visual inspection on the ELGA unit for grease leakage.

For severe applications or if ELGA operation is infrequent, perform maintenance checks at

shorter intervals.

Important

Regular checks may be determined by the specific environmental and

working conditions.

6.2 Special Maintenance

Approx. every 200 working hours, restore the greasing of the lead screw inside the housing, by

removing the cover.

Periodically check, and if necessary restore, the lubrication of the reduction unit.

Restore periodically the rolling bearings lubrication introducing grease by means of the grease

nipple.

In case of malfunction or in case of grease leaks or in case of scheduled preventive

maintenance, the ELGA unit must be disassembled: any damaged part can be requested to

BIFFI with reference to the attached exploded view drawing and parts list.



Every spare parts request has to clearly indicate the relevant ELGA Serial Number and the spare

part item number.

Special maintenance is also recommended when, during operations, the actuator generates an

excessive noise.

Important

After maintenance works, a few operations of the assembly actuator/ELGA

must be done to check that movement is regular.

Important

For the maintenance instructions of the Electric Actuator ICON2000 supplied

together with the ELGA reduction unit, please refer to the ICON2000 IOM

(MAN 618).



7 LUBRICATION

In case of maintenance the following lubricants are recommended:

For the scotch yoke mechanism use grease type indicated in the following table:

AGIP MU/EP/2 or equivalent AEROSHELL GREASE 7 or equivalent

To be used in standard temperature

conditions (-30°C/+85°C)

NLGI consistency: 2

Worked penetration: 280 dmm

ASTM Dropping Point: 185°C

Base oil viscosity at 40°C: 160 mm²/s

ISO Classification: L-X-BCHB 2

DIN 51 825: KP2K - 20

To be used in low temperature conditions

(-60°C/+65°C)

Colour: Buff

Physical state: Semi-solid at ambient temperature

Odour : Slight

Density : 966 Kg/m³ at 15°C

Flash Point : ›215°C (COC)(Based on synthetic oil)

Dropping point : 260°C (ASTM D-566)

Product code : 001A0065

Infosafe No.: ACISO GB/eng/C

For the reduction unit use oil type indicated in the following table:

SHELL – OMALA S4 WE 320

(or equivalent)

SHELL – TELLUS S4 ME 46

(or equivalent)

To be used in standard temperature conditions

(-30°C/+85°C)

ISO Viscosity grade ISO 3448 : 320

Kinematic Viscosity ISO 3104 at 40°C : 321 mm²/s

Kinematic Viscosity ISO 3104 at 100°C : 52.7 mm²/s

Viscosity index ISO 2909: 230

Flash Point COC ISO 2592 : 286°C

Pour point ISO 3016 : -39°C


FZG Load Carryng Test Failure load stage DIN

51354-2 A/8.3/90 : ›12

To be used in low temperature conditions

(-60°C/+65°C)

ISO Fluid type : HM

Kinematic Viscosity ASTM D445 at 0°C: 450 cSt

Kinematic Viscosity ASTM D445 at 40°C: 46 cSt

Kinematic Viscosity ASTM D445 at 100°C: 7.7 cSt


Density at 15°C (ISO 12185): 0.832 Kg/l

Flash Point (ISO 2592) : 250 °C

Pour Point (ISO 3016) : -51°C



8 ADJUSTING THE MECHANICAL STOPPERS

Please refer to the following Picture 3 for Close position.

Loose the nut (1).

Loose the stopper (2) with an hex-head wrench. Stopper shall be taken out as much as

possible from the body of the gear.

Move the ELGA to the end Close position and set-up the stroke limits.

Tighten the stopper (2) until it stops, then step back one turn.

Tighten the nut (1).

For the Open position please follow the same procedure described above, on the opposite stopper.

This must be done with the actuator/ELGA installed onto the valve, with the valve in completely open or

close position.

Picture 3

(1)



9 DISMANTLING AND DEMOLITION

Warning

The actuator demolition must be done by specialised personnel.

Before starting dismounting, it is advisable to create sufficient space around the ELGA so as to allow

movement and not cause any environment-induced risks.

Separate the ELGA components according to their nature (i.e. metal parts, plastic, fluids, etc.) and dispose

them properly, as indicated by the laws in force and in the following table:

Subject Hazardous Recyclable Disposal

Electrical and electronic

equipment

YES YES Use specialist recyclers

Glass NO YES Use specialist recyclers

Metals NO YES Use licensed recyclers

Plastics NO YES Use specialist recyclers

Rubber (seals and O-

rings)

YES NO Will require special treatment before disposal, use

specialist waste disposal companies

Oil and grease YES YES Will require special treatment before disposal, use


Batteries YES YES Will require special treatment before disposal, use


Warning

Do not re-use parts or components which appear to be good condition after

they have been checked or replaced by qualified personnel and declared

unsuitable for use.

Important

In all cases check local authority regulation before disposal.



10 PARTS LIST

10.1 How to Order Parts List

To order parts or obtain further information about Biffi valve operator, contact your local distributor sales

office or:

Biffi Italia S.r.l.

Località Caselle San Pietro

29017 FIORENZUOLA D’ARDA

PIACENZA (ITALY)

Telephone: 0039 0523 944 411

Fax: 0039 0523 944 546

All inquiries and orders must be accompanied by the following information, which are located in the

nameplate:

1. Operators model, size and ratio;

2. Order number;

3. Serial number.



BIFFI ITALIA s.r.l.

Loc. Caselle S. Pietro

29017 Fiorenzuola d’Arda -Piacenza - ITALY -

Tel. (0523) 944411 - Fax (0523) 941885

E_mail: [email protected]

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